Thermally constrained high temperature optical fiber holder

ABSTRACT

A disclosed probe assembly includes a sensor member and an outer holder including a main bore for the sensor member, the outer holder including a first coefficient of thermal expansion. The sensor member is held within a sensor bore of an inner holder. The inner holder is held within the main bore of the outer holder by an interference fit. The inner holder includes a second coefficient of thermal expansion greater than the first coefficient of thermal expansion. Expansion of the inner holder is constrained by the outer holder to maintain the sensor member within the probe bore of the inner holder at elevated temperatures.

BACKGROUND

This disclosure relates generally to the assembly of an optical probeand, more particularly, to a mounting assembly for retaining opticalcomponents in a high temperature environment of a gas turbine engine.

A gas turbine engine typically includes a fan section, a compressorsection, a combustor section and a turbine section. Air entering thecompressor section is compressed and delivered into the combustionsection where it is mixed with fuel and ignited to generate a high-speedexhaust gas flow. The high-speed exhaust gas flow expands through theturbine section to drive the compressor and the fan section.

Measurement and observation of components during operation of a gasturbine engine can be useful in improving overall operationalefficiency. Probes are utilized in tip-timing systems that observe andmeasure arrival times of rotor, compressor or fan blades. One type ofprobe utilizes an optical fiber mounted within a static structureproximate the rotating blade. Such mounting locations expose the opticalfiber to extreme temperature environment within the engine. Opticalfibers are typically adhered by an epoxy to probe housings which areheld within apertures of the case structure. Epoxy is susceptible tofailure due to exposure to extreme temperatures encountered duringoperation. It is therefore desirable to design and develop simplifiedmounting structures for probes and or other optical components that arecompatible at high temperature and extreme environments.

SUMMARY

A probe assembly according to an exemplary embodiment of thisdisclosure, among other possible things includes a sensor member, and aholder including a sensor bore receiving the sensor member. The holderincludes a coefficient of thermal expansion greater than a coefficientof thermal expansion of the sensor member.

In a further embodiment of the foregoing probe assembly, the holdercomprises an outer holder which includes a main bore for the sensormember. The outer holder includes a first coefficient of thermalexpansion. An inner holder includes a sensor bore receiving the sensormember. The inner holder is disposed within the main bore. The innerholder includes a second coefficient of thermal expansion greater thanthe first coefficient of thermal expansion.

In a further embodiment of any of the foregoing probe assemblies, thesensor member comprises an optical fiber.

In a further embodiment of any of the foregoing probe assemblies, thesensor member includes a coefficient of thermal expansion substantiallysimilar to the outer holder.

In a further embodiment of any of the foregoing probe assemblies, themain bore includes a first end open to a sensed object with the innerholder disposed near the first end.

In a further embodiment of any of the foregoing probe assemblies, themain bore includes a lip at the first end for holding the inner holderwithin the bore.

In a further embodiment of any of the foregoing probe assemblies,includes a lens received within the main bore at the first end.

In a further embodiment of any of the foregoing probe assemblies, thelens is disposed within a lens housing that is in turn disposed withinthe main bore. The lens housing includes a coefficient of thermalexpansion greater than that of the outer housing.

A gas turbine engine case assembly according to an exemplary embodimentof this disclosure, among other possible things includes a case providedabout a rotational axis of a gas turbine engine, and at least one probeassembly supported within the case. The probe assembly includes a sensormember, and an outer holder including a main bore for the sensor member.The outer holder includes a first coefficient of thermal expansion. Aninner holder includes a sensor bore receiving the sensor member. Theinner holder is disposed within the main bore. The inner holder includesa second coefficient of thermal expansion greater than the firstcoefficient of thermal expansion.

In a further embodiment of the foregoing gas turbine engine caseassembly, the sensor member comprises an optical fiber.

In a further embodiment of any of the foregoing gas turbine engine caseassemblies, the main bore includes a first end open to a sensed objectwith the inner holder disposed near the first end.

In a further embodiment of any of the foregoing gas turbine engine caseassemblies, the main bore includes a lip at the first end for holdingthe inner holder within the bore.

In a further embodiment of any of the foregoing gas turbine engine caseassemblies, includes a lens received within the main bore at the firstend.

In a further embodiment of any of the foregoing gas turbine engine caseassemblies, includes a lens holder receiving the lens and fit within themain bore. The lens holder has a coefficient of thermal expansiongreater than that of outer housing.

In a further embodiment of any of the foregoing gas turbine engine caseassemblies, the sensor bore includes a relief expanding radiallyoutward.

In a further embodiment of any of the foregoing gas turbine engine caseassemblies, the probe assembly includes a probe housing supporting theouter holder and the case includes openings for the receiving the probehousing.

A method of retaining a probe within a gas turbine engine according toan exemplary embodiment of this disclosure, among other possible thingsincludes assembling a probe member into a probe bore defined within aninner holder, inserting an inner holder within a main bore definedwithin an outer holder. The inner holder includes a coefficient ofthermal expansion greater than the outer holder, and inserting outerholder within an opening of a static structure of a gas turbine engine.

In a further embodiment of the foregoing method, includes the step ofheating the inner holder to expand the probe bore to receive the probemember followed by subsequent cooling of the inner holder once the probeis inserted into the inner holder.

In a further embodiment of any of the foregoing methods, includes thestep of heating the outer holder to expand the main bore to receive theinner holder followed by subsequent cooling of the outer holder once theinner holder is inserted within the main bore.

In a further embodiment of any of the foregoing methods, includes thestep of installing a lens within a lens housing by heating the lenshousing and inserting the lens within the lens housing followed bycooling to room temperature and subsequent insertion into the main boreproximate an end of the probe member.

Although the different examples have the specific components shown inthe illustrations, embodiments of this disclosure are not limited tothose particular combinations. It is possible to use some of thecomponents or features from one of the examples in combination withfeatures or components from another one of the examples.

These and other features disclosed herein can be best understood fromthe following specification and drawings, the following of which is abrief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an example gas turbine engine.

FIG. 2 is a schematic view of an example case structure for the examplegas turbine engine.

FIG. 3 is a sectional view of an example sensor assembly.

FIG. 4 is an enlarged view of an inner housing of an example probeassembly.

FIG. 5 is a schematic view of another example probe assembly.

FIG. 6 is a perspective view of an end portion of another example probeassembly.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates an example gas turbine engine 20 thatincludes a fan section 22, a compressor section 24, a combustor section26 and a turbine section 28. Alternative engines might include anaugmenter section (not shown) among other systems or features. The fansection 22 drives air along a bypass flow path B while the compressorsection 24 draws air in along a core flow path C where air is compressedand communicated to a combustor section 26. In the combustor section 26,air is mixed with fuel and ignited to generate a high pressure exhaustgas stream that expands through the turbine section 28 where energy isextracted and utilized to drive the fan section 22 and the compressorsection 24.

Although the disclosed non-limiting embodiment depicts a turbofan gasturbine engine, it should be understood that the concepts describedherein are not limited to use with turbofans as the teachings may beapplied to other types of turbine engines; for example a turbine engineincluding a three-spool architecture in which three spoolsconcentrically rotate about a common axis and where a low spool enablesa low pressure turbine to drive a fan via a gearbox, an intermediatespool that enables an intermediate pressure turbine to drive a firstcompressor of the compressor section, and a high spool that enables ahigh pressure turbine to drive a high pressure compressor of thecompressor section. Moreover, an industrial gas turbine engine utilizedfor producing power may also benefit from this disclosure.

The example engine 20 generally includes a low speed spool 30 and a highspeed spool 32 mounted for rotation about an engine central longitudinalaxis A relative to an engine static structure 36 via several bearingsystems 38. It should be understood that various bearing systems 38 atvarious locations may alternatively or additionally be provided.

The low speed spool 30 generally includes an inner shaft 40 thatconnects a fan 42 and a low pressure (or first) compressor section 44 toa low pressure (or first) turbine section 46. The inner shaft 40 drivesthe fan 42 through a speed change device, such as a geared architecture48, to drive the fan 42 at a lower speed than the low speed spool 30.The high-speed spool 32 includes an outer shaft 50 that interconnects ahigh pressure (or second) compressor section 52 and a high pressure (orsecond) turbine section 54. The inner shaft 40 and the outer shaft 50are concentric and rotate via the bearing systems 38 about the enginecentral longitudinal axis A.

A combustor 56 is arranged between the high pressure compressor 52 andthe high pressure turbine 54. In one example, the high pressure turbine54 includes at least two stages to provide a double stage high pressureturbine 54. In another example, the high pressure turbine 54 includesonly a single stage. As used herein, a “high pressure” compressor orturbine experiences a higher pressure than a corresponding “lowpressure” compressor or turbine.

The example low pressure turbine 46 has a pressure ratio that is greaterthan about 5. The pressure ratio of the example low pressure turbine 46is measured prior to an inlet of the low pressure turbine 46 as relatedto the pressure measured at the outlet of the low pressure turbine 46prior to an exhaust nozzle.

A mid-turbine frame 58 of the engine static structure 36 is arrangedgenerally between the high pressure turbine 54 and the low pressureturbine 46. The mid-turbine frame 58 further supports bearing systems 38in the turbine section 28 as well as setting airflow entering the lowpressure turbine 46.

The core airflow C is compressed by the low pressure compressor 44 thenby the high pressure compressor 52 mixed with fuel and ignited in thecombustor 56 to produce high speed exhaust gases that are then expandedthrough the high pressure turbine 54 and low pressure turbine 46. Themid-turbine frame 58 includes vanes 60, which are in the core airflowpath and function as an inlet guide vane for the low pressure turbine46. Utilizing the vane 60 of the mid-turbine frame 58 as the inlet guidevane for low pressure turbine 46 decreases the length of the lowpressure turbine 46 without increasing the axial length of themid-turbine frame 58. Reducing or eliminating the number of vanes in thelow pressure turbine 46 shortens the axial length of the turbine section28. Thus, the compactness of the gas turbine engine 20 is increased anda higher power density may be achieved.

The disclosed gas turbine engine 20 in one example is a high-bypassgeared aircraft engine. In a further example, the gas turbine engine 20includes a bypass ratio greater than about six (6), with an exampleembodiment being greater than about ten (10). The example gearedarchitecture 48 is an epicyclical gear train, such as a planetary gearsystem, star gear system or other known gear system, with a gearreduction ratio of greater than about 2.3.

In one disclosed embodiment, the gas turbine engine 20 includes a bypassratio greater than about ten (10:1) and the fan diameter issignificantly larger than an outer diameter of the low pressurecompressor 44. It should be understood, however, that the aboveparameters are only exemplary of one embodiment of a gas turbine engineincluding a geared architecture and that the present disclosure isapplicable to other gas turbine engines.

A significant amount of thrust is provided by the bypass flow B due tothe high bypass ratio. The fan section 22 of the engine 20 is designedfor a particular flight condition—typically cruise at about 0.8 Mach andabout 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft., withthe engine at its best fuel consumption—also known as “bucket cruiseThrust Specific Fuel Consumption (‘TSFC’)”—is the industry standardparameter of pound-mass (1 bm) of fuel per hour being burned divided bypound-force (1 bf) of thrust the engine produces at that minimum point.

“Low fan pressure ratio” is the pressure ratio across the fan bladealone, without a Fan Exit Guide Vane (“FEGV”) system. The low fanpressure ratio as disclosed herein according to one non-limitingembodiment is less than about 1.50. In another non-limiting embodimentthe low fan pressure ratio is less than about 1.45.

“Low corrected fan tip speed” is the actual fan tip speed in ft/secdivided by an industry standard temperature correction of [(Tram°R)/(518.7°R)]^(0.5). The “Low corrected fan tip speed”, as disclosedherein according to one non-limiting embodiment, is less than about 1150ft/second.

The example gas turbine engine includes the fan 42 that comprises in onenon-limiting embodiment less than about 26 fan blades. In anothernon-limiting embodiment, the fan section 22 includes less than about 20fan blades. Moreover, in one disclosed embodiment the low pressureturbine 46 includes no more than about 6 turbine rotors schematicallyindicated at 34. In another non-limiting example embodiment the lowpressure turbine 46 includes about 3 turbine rotors. A ratio between thenumber of fan blades 42 and the number of low pressure turbine rotors isbetween about 3.3 and about 8.6. The example low pressure turbine 46provides the driving power to rotate the fan section 22 and thereforethe relationship between the number of turbine rotors 34 in the lowpressure turbine 46 and the number of blades 42 in the fan section 22disclose an example gas turbine engine 20 with increased power transferefficiency.

The example gas turbine engine 20 includes a compressor case 62 that ispart of the engine static structure 36. The compressor case 62 surroundsthe high pressure compressor 52.

Referring to FIG. 2 with continued reference to FIG. 1, the example casestructure 62 surrounds the compressor 52 and rotating blades indicatedschematically by dashed lines at 68 that rotate proximate to the casestructure 62. The example case structure 62 includes a plurality ofsensor assemblies 64 that communicate with the controller 66. The sensorassemblies 64 are utilized in this example to detect passing the blades68. Detection of a blade 68 as it passes one of the sensor assemblies 64is utilized for tip timing functions and other health monitoringfeatures of the example gas turbine engine 20. The high pressurecompressor 52 operates at elevated temperatures and therefore requiresthat the sensor assemblies 64 are suitable for operation at suchelevated temperatures.

Referring to FIG. 3, an example sensor assembly 64 includes a firstprobe assembly 65 a and a second probe assembly 65 b. Each of theexample probe assemblies 65 a-b is substantially similar inconfiguration. The probe assemblies 65 a and 65 b are disposed within acommon housing 100. The housing 100 is provided for supporting the probeassembly 65 a and 65 b and is mountable within the case structure 62.

Each of the probe assemblies 65 a and 65 b include a sensor member. Inthe disclosed example, the sensor member comprises an optical fiber 72.The optical fiber 72 is held within an inner holder 86 supported withinan outer holder 74 that is in turn supported within the housing 100. Theinner holder 86 is fit by way of an interference fit within a main bore80 of the outer holder 74. The outer holder 74 is held within thehousing 100 by a fastening member 75. The fastening member 75 holds bothouter holders 74 of each of the probe assemblies 65 a, 65 b within thehousing 100. In this example, the fastener 75 is a threaded member thatis secured to the housing 100. However, other fastening structures andmethods, such as a weld 84 may be utilized to hold each of the outerholders 74 within the housing 100 and are within the contemplation ofthis disclosure. Moreover, the housing 100 may be held within the case62 by welds, fasteners along with any other fastening process compatiblewith the environment of the engine 20.

The optical fiber 72 is held within the inner holder 86 by aninterference fit. The interference fit provides sufficient frictionalengagement on the optical fiber 72 to hold an end 90 of the opticalfiber 72 in a desired orientation relative to the probe end 76 of thesensor assembly 64. An outer end 78 of the optical fiber 72 extends outof the fastener member 75. The inner holder 86 includes a coefficient ofthermal expansion that is much greater than the coefficient of thermalexpansion of the optical fiber 72. Because the inner holder 86 has acoefficient of thermal expansion that is much higher than the opticalfiber 72, the inner holder 86 may be heated to a temperature thatexpands the inner diameter an amount determined to receive the opticalfiber 72 and provide for placement of the optical fiber 72 within theinner holder 86. Upon cooling of the inner holder 86, the inner diameterwill shrink such that it will hold the optical fiber 72 within the innerholder 86 with the desired interference fit.

The outer holder 74 includes a second coefficient of thermal expansionthat is much less than that of the inner holder 86. The outer holder 74is heated to a temperature that allows for the inner holder 86 to slidewithin the bore 82 and the probe end 76. Once the inner holder 86 ispositioned as is desired within the outer holder 74, the outer holder 74and the inner holder 86 are cooled to room temperature such that aninterference fit is created between the inner holder 86 and the bore 80of the outer holder 74.

The bore 80 of the outer holder 74 includes a lip 94 that abuts theinner holder 86 and positions the inner holder 86 within the bore 80proximate opening 96. As appreciated, although a lip 94 is shown in theillustrated and disclosed embodiment, other features for locating theinner holder 86 could also be utilized.

A lens 92 is received within the housing 100 proximate to the outerholder 74. In this example, the lens 92 is secured within the housing100 proximate the probe ends 76 by way of an epoxy or other adhesivefastening compound.

Referring to FIG. 4 within continued reference to FIG. 3, the exampleinner holder 86 is shown disposed within the bore 80 of the outer holder74. The inner holder 86 includes the bore 88 that receives the opticalfiber 72. A relief 98 is disposed at one end of the bore 88 to allowsome movement and substantially reduce the possibility of damage to theoptical fiber 72. The bore 88 is sized to provide an interference fitwith optical fibers 72 when both the optical fiber 72 and inner holder86 are at a common temperature.

The inner holder 86 includes a coefficient of thermal expansion that ismuch greater than that of the optical fiber 72. In the disclosedexample, the optical fiber 72 includes a coefficient of linear thermalexpansion that is between approximately 4.0 and 5.0 micro-inch/inch/° F.The inner holder 86 includes a coefficient of linear thermal expansionthat is between approximately 10 and 14 micro-inch/inch/° F.

As should be appreciated the coefficient of thermal expansion may referto a volumetric, area and linear changes in a structures dimensions dueto exposure to elevated temperatures. In the disclosed example the unitsof thermal expansion are provided with reference to linear thermalexpansion, however volumetric and area expansion due to temperature arealso within the contemplation of this disclosure.

In this example, the inner holder 86 comprises a stainless steelmaterial within a very high coefficient of thermal expansion as comparedto the optical fiber 72. The difference in rates of thermal expansionbetween the inner holder 86 and the optical fiber 72 provide for theinner holder 86 to be heated to a relatively low temperature while stillexpanding the bore 88 sufficiently to receive the optical fiber 72. Uponcooling of the inner holder 86, the bore 88 will contract and generatethe desired interference fit with the optical fiber 72.

The outer holder 74 includes a coefficient of linear thermal expansionof between approximately 4.0 and 6.0 micro-inch/inch/° F. The relativelylow coefficient of linear thermal expansion provides a counter actingmeans to prevent the optical fiber 72 from being released from the bore88 of the inner holder 86.

During operation elevated temperatures of the sensor assembly 64 willheat the inner holder 86 and the outer holder 74. Because the innerholder 86 has a much higher coefficient of thermal expansion, it willattempt to expand such that bore 88 may open to a diameter that wouldallow the optical fiber 72 to shift from its desired position. However,because the inner holder 86 is disposed within the outer holder 74 andthe outer holder 74 includes a coefficient of thermal expansion that ismuch lower than that of the inner holder 88, the outward expansion ofthe inner holder 86 is constrained by the outer holder 74 such that thebore 88 does not open under extreme temperatures and the optical fiber72 is maintained in a desired orientation relative to the probe end 76.

Referring to FIG. 5, another probe assembly 102 is illustrated andincludes a lens 110 that is held within a lens housing 108. The lenshousing 108 includes a material with a high coefficient of thermalexpansion much like that of the inner holder 86. The lens 110 isreceived within a bore 114 defined within the lens housing 108. The lenshousing 108 is heated to a temperature that expands the bore 114 suchthat the lens 110 may be received within the lens housing 108. Once thelens housing 108 cools to room temperature, a desired interference fitis formed that holds 110 relative to the probe housing 108.

The probe housing 108 is then inserted within a bore 106 of the outerholder 104. The bore 106 is extended a sufficient length to receive thelens 110 disposed within the lens housing 108. The extended length movesthe lip 112 for holding the lens 110 at a desired position within thebore 106. As appreciated, a specific spacing between the optical fiber72 and the lens 110 as is indicated at 116 is desired. The distance 116can be adjusted by specifically locating the inner holder 86 relative tothe probe housing 108.

In this example where the lens 110 is mounted within the lens housing108 and is maintained by the desired interference fit eliminates theneed for epoxy to support the lens 110 within the housing 100.Accordingly, the example embodiment illustrated in FIG. 5 provides forthe use of a focused probe assembly 102 that does require epoxy or otheradhesives to maintain the lens 110 in a desired orientation relative toan end of the optical fiber 72.

Referring to FIG. 6, an unfocused probe assembly 118 is illustrated thatdoes not include a lens. In some sensor applications, an unfocused probecan be utilized and provides sufficient data to facilitate the healthmonitoring of the gas turbine engine as is required. Accordingly, FIG. 6illustrates the probe assembly 118 that includes the inner holder 86that holds the optical fiber 72 within the outer holder 74. The outerholder 74 does not support a lens and therefore does not requireadditional structure required for holding the lens.

Accordingly, the example sensor assembly includes a mounting arrangementthat does not require epoxy welding or other adhesives to withstand theextreme temperatures and conditions during operation of the gas turbineengine. Moreover, the example sensor assembly provides a probe assemblythat can be mounted and assembled without the use of adhesives or othertemperature sensitive materials.

Although an example embodiment has been disclosed, a worker of ordinaryskill in this art would recognize that certain modifications would comewithin the scope of this disclosure. For that reason, the followingclaims should be studied to determine the scope and content of thisdisclosure.

What is claimed is:
 1. A probe assembly comprising: a sensor member; aholder including a sensor bore receiving the sensor member, the holderincluding a coefficient of thermal expansion greater than a coefficientof thermal expansion of the sensor member.
 2. The probe assembly asrecited in claim 1, wherein the holder comprises an outer holderincluding a main bore for the sensor member, the outer holder includinga first coefficient of thermal expansion; and an inner holder includinga sensor bore receiving the sensor member, the inner holder disposedwithin the main bore, wherein the inner holder includes a secondcoefficient of thermal expansion greater than the first coefficient ofthermal expansion.
 3. The probe assembly as recited in claim 2, whereinthe sensor member comprises an optical fiber.
 4. The probe assembly asrecited in claim 2, wherein the sensor member includes a coefficient ofthermal expansion substantially similar to the outer holder.
 5. Theprobe assembly as recited in claim 2, wherein the main bore includes afirst end open to a sensed object with the inner holder disposed nearthe first end.
 6. The probe assembly as recited in claim 5, wherein themain bore includes a lip at the first end for holding the inner holderwithin the bore.
 7. The probe assembly as recited in claim 5, includinga lens received within the main bore at the first end.
 8. The probeassembly as recited in claim 7, wherein the lens is disposed within alens housing that is in turn disposed within the main bore, wherein thelens housing includes a coefficient of thermal expansion greater thanthat of the outer housing.
 9. A gas turbine engine case assemblycomprising: a case provided about a rotational axis of a gas turbineengine; and at least one probe assembly supported within the case withthe probe assembly including; a sensor member; an outer holder includinga main bore for the sensor member, the outer holder including a firstcoefficient of thermal expansion; and an inner holder including a sensorbore receiving the sensor member, the inner holder disposed within themain bore, wherein the inner holder includes a second coefficient ofthermal expansion greater than the first coefficient of thermalexpansion.
 10. The gas turbine engine case assembly as recited in claim9, wherein the sensor member comprises an optical fiber.
 11. The gasturbine engine case assembly as recited in claim 9, wherein the mainbore includes a first end open to a sensed object with the inner holderdisposed near the first end.
 12. The gas turbine engine case assembly asrecited in claim 11, wherein the main bore includes a lip at the firstend for holding the inner holder within the bore.
 13. The gas turbineengine case assembly as recited in claim 12, including a lens receivedwithin the main bore at the first end.
 14. The gas turbine engine caseassembly as recited in claim 13, including a lens holder receiving thelens and fit within the main bore, the lens holder having a coefficientof thermal expansion greater than that of outer housing.
 15. The gasturbine engine case assembly as recited in claim 9, wherein the sensorbore includes a relief expanding radially outward.
 16. The gas turbineengine case assembly as recited in claim 9, the probe assembly includesa probe housing supporting the outer holder and the case includesopenings for the receiving the probe housing.
 17. A method of retaininga probe within a gas turbine engine comprising: assembling a probemember into a probe bore defined within an inner holder; inserting aninner holder within a main bore defined within an outer holder, whereinthe inner holder includes a coefficient of thermal expansion greaterthan the outer holder; and inserting outer holder within an opening of astatic structure of a gas turbine engine.
 18. The method as recited inclaim 17, including the step of heating the inner holder to expand theprobe bore to receive the probe member followed by subsequent cooling ofthe inner holder once the probe is inserted into the inner holder. 19.The method as recited in claim 18, including the step of heating theouter holder to expand the main bore to receive the inner holderfollowed by subsequent cooling of the outer holder once the inner holderis inserted within the main bore.
 20. The method as recited in claim 19,including the step of installing a lens within a lens housing by heatingthe lens housing and inserting the lens within the lens housing followedby cooling to room temperature and subsequent insertion into the mainbore proximate an end of the probe member.